Process of making compound hollow metal bodies.



E. G. 000K. PROCESS 0F MAKIG GOMPOUND HOLLGW METAL BODIES.

APPLICATION FILED PEB. 14, 1912.

.ess of may be made manifold.

EDWARD e; Coon, 'or encouru; NEW Y :Paonuc'rs COMPANY,

rnccnss ernannte conroUNn HOLLOW Junren BODIES.

Yoannssienon. -ro-BnAss e COPPER, ornnwronnnr Locatie.

Specification of Letters Patent. l Piellted Jun@ 3, 1913.

appucaiin .eieereeruary 14, 1912. serial no. 677,507.

To all wko/m; t mag/concern: Be it known that I, EDWARD G.,CooK,a citizen of the United. States, residing .in Brooklyn, New York, in the county 'of Kings and' Sta-teef New York, have ,invented-cer- Itam new and useful-Improvements in Proc'- essesof MakingCompound Hollow-Metal Bodies, of which the following is aspeciti-4 cationf v, My present improvement relatesto a procmanufacture ofv articles comprised of hollow or tubularmetal bodies.

For the purposeof illustrating forms that by my process and also to,y bring out the utility thereof, have shown in the accompanying drawings, a tubular body known as a Water-jacketed gas engine l :One of the advantages of articles made by the walls can .be thinner than 1s customarily obtained by the 'usual methodof casting.

A further advantage of this. Aprocess is that hollow or tubular bodies requiring a 'a plastic material or plurality of walls may be made thereby, it being impossible or impracticable to make such bodies by vany other known-imethod.

A further advantage -ofarticles made by my process is that they are light and with proper care in the process of making, strength is made consistent with lightness.

In the accompanying drawings, Figure 1 is a sectifffzal View of an article made by my process taken on the line 2-2, Fig. 2, Fig. 2 is a sectional view taken on the line 1--l,

Fig. 1, Fig. 3 is a sectional View of a manifold, Fig. 4 is a sectional view of a modification of Fig. 2, and Fig. 5 is a view of another modification.

As one indication of the construction that may be made 'by my process, there is shown in Fig. 1 a longitudinal section of two hollow metal lbodies 2 and 3, which, as shown in Fig. 2, may be cylindrical, although the shape there shown may be of any section desired. In the interior is shown a core or forming member 4 which is comprised of compoundwhich may be of wax or any material of .like nature, the said material being so cast in a mold or sectional being 'formed by. hand that-its outer contour sii-ed.

may-be used to shape thelmetal articlede- In the present-.case inV Figs.V 1 and 2 the i object 'to be made 1s comprised or" two metal l ls ired thickness of outside with another Zbath held apart in normally relative positions to yone another by means 'of chaplets 5, 6, 7' and -8. g The/corev form vit after being properly shaped is .coated with a light metallic powder, such as graphite or bronze powden-to form a conductive-surface thereon, and 1s; immerse in the well known coptubes being per bath and is caused to have coated theres on, by an electric current, a. deposit of copper. `This process iscontinued until the de- Wall 3y is shown in Fig. 5. The articleis then-removed from thebath and is coated on the coating 9v of acompound similar to that used for the core form 4. This will form or the outside of the tubular member3 another master or core form 2 and after cutting pocket-s in various places in the said form 9,- so as to permit the chaplets 5, 6, 7 and' 8 to be formed, the article is thenv re-immersed in the copper and coating repeated until. the' Wall 2 of the desired thickness is formed externally thereon.- The tubes are then cut through at the points AB and CD, Fig. 1, and the article may then be immersed in hot water, thisk causing the coreto become' fluid leaving two 4cylindrical bodies relatively iXed to one another and r'ady for any purpose. that may be required- As an indication of some of the more complicated forms that may be mad'e by this process, there shown in Fig. 3 a carbu reter intake manifold for gas engines which is arranged so that the inner passageway 10 which connects the four passageways 11,

12, I13 and 14, is a passage for distributing known in carbureti'ug gasoleue for that ythe mixing of air and gasolene to make an. explosive charge, reduces the temperature of air surrounding the intake pipe to such an extent thatkthe pipo sometimes becomes frosted and to overcome this difficulty a Water jacketed manifold is used that is so arranged to permit the circulation of the heated Waterfrom the engine water jackets to flow around the said intake pipe. The customary method ofimaking this manifold heretofore has been by the well known foundry method ofcasting and the principal objection to class ci work is the uueveimess of that walls together with -i'he engines and l obtained las lid great weight of the same, 1t.be1ng impos-- bodies consisting of forming-a body of sible to cast as thm a wall as could be used. -plastic material in the desired shape and The core form for the manifold shown in electro-depositing a coating of metal upon Fi'- 3 is made' m tlm usulfsyl, and in the said form, then forming a body lof plasmanufacturing, a mold for these core forms tic material upon said metal coating and may be made so that the work resulting electro-depositing upon said second plastic therefrom would be of uniform dimensions material another coating of metal.

and after the process of depositing the [irst or inner wall 16 has been concluded, the bodies consisting in shaping a body of plasshell formed thereby is coated as described tic material to the desired contour, and'eleC- for Fig. Vl, and treated at the points 17, 18 tro-depositing a iilm of metal upon said and 19, so as to obtain chaplets or holding form, and then coatingI the metal body y in the fiuid state and left thereafter to set.

members between the two tubular members, formed -thereby with a covering of plastic 2. A process of making hollow metal and then the outer shell is deposited upon material of the desired thickness, and forming notches thereon in desired places m the said coating, lsaid notches being formed by the removal of said plastic coating until the vmetal of the first said coating is exposed, and then coating the said plastic body with acovering` of metal of 'the desired thickness the second core form, which is comprised of the inner core form, its metal coating and the plastic coat-ing on the exteriorthereof. This procedure, as in the case of l? ig. i, would leave a metal body inclosed all around as indicated at the ends 20,21, 22, 23, and For the purpose of removing the interior plastic forms from the gas passageway 10 andthe water passageway 10, the ends are cut on the lines indicated `by af, gh, z'j, kl and ma, thereby forming a double walled manifold for the purpose described.

Additional treatment may be required to put this manifold in condition for use on a gas engine, such as attaching at the out points, vby means of brazing, attaching flanges, but they are not shown in the pres ent drawing for the reason that (they form no part of the process. l It is obvious that any of the articles made by the above noted process can be treated by polishing and buting, so that they may have a smooth satin finish, or highly polished surfaces. It is also obvious that devices of this class may be made to have walls of metal of' thinner proportions than has heretofore been possible by any other method now used. As a further indication of the possibilities of this process in manufacturing articles of the class previously described, I have shown in Fig. et where the process has been continued one step further, wherein the second tubular member has been coated and a third v. metal member formed thereon havingthis chaplet attaching means t-herebtween, there' by forming a three walled tubular member comprised of walls 25, 26 and 27, the said walls forming thereby, the passageways 28, 29 and 30. lf a manifold shown in Fig. 3 were constructed according to the section the body of metal formed thereby with'a shown in Fig. d, the passageway 28 could be coating of like plastic material, and proused as a gas conducting passage, the pas'- vidingvopenings in said plastic material at into the said plastic ,coating thereby forining connecting members or chaplets between the two said metal bodies. bodies consisting in forming a body of plastic material of the desired contour, andV electro-depositing a film of nieta-l upon said formed thereby with a covering of plastic material lof the desired thickness, and forming notches thereon in desired places in the Asaid coating, said notches 'being formed by the removal of said plastic `coating until the metal of the first said coating is exposed, and then coating the said plasticv body with al covering of metal of the-de sired thickness, by electro-deposition, the said notchescut into the said plastic coating thereby forming connecting members or chaplets between the two said metal-bodies, the two" attaching meta-l bodies formed thereby being` then cut at pre-determined places and being immersed in boiling water thereby to remove the plastic core forms and leaving a pair. of 'connected tubular memA bers.

bodies, comprised of a plurality fof metal bodies, one inside the otherand of like contour, consisting of moldinga' plastic matelirst or interior body, and electro-depositing thereon a coating of metal and covering sagewa'y Q9 being used as a water Jacketed ythe desired points and coating the saidpassageway,and the passa-ge 30- may be filled with an insulating compound, such as astro-deposition, and again coating the formed bestos and magnesia which might be applied metal body with a coatingl of plasticmate rial of requisite thickness and providing Y Having thus` described my invention, l openings the second said plastic wall at claim: Y,

il. A p for making hollow meta v said second plastic form withan outer coatby electro-deposition, the said notches eut 3.y A process of making hollow. metal' form, and then coating the metalv body 4. A Aprocess of making holiow metalrial like wax into the desired shape ofV theplast-ic wall with a coating of metal byelecl ing of metal by electro-deposition, the said openings formed in the tic Wall formed thereby at pre-determined points and. lllmersing the said bodies in aboiling fluid thereby causing the said plastic 'matel to become Huid andv leaving a three walled metal body. v

5, A process for making hollow metal bodies consisting of electro-depositing av metal coating upon a plastic core form and rthen by successive coa then by successive coatings of plastic mate-A rial and electro-depositing of metal thereon, to form a ,multi-walledhollow metal body, Y 6, A process for making compound hollow metal bodies, consisting of electro-depositing a metal coating upon a` plastic core form and ings of plastic material and electro-depositing of metal to form a' multi-walled hollow body, said walls be'ng connected together by means of chapets. 7, A process y p metal bodies, consisting of electro-depositing a metal coating upon a core', form and then terial and electro-deposit1ng of metal on a multi-walled hollow metal body, said vvallsY being connected together by means of chaplets formed of electro-deposited lmetal, openings being provided in the plastic cores belets and cuttm' g bodies iat certain 'i .thereby causing the plastic material- .then 'cuttlng olf the ends of foi` making compound hollow metal bodies of like by successive coatings of plastic mal' other.

tween said walls thereby to form said chappre-determined places and immers'ing the article in vbof Water, come fluid and be thereby removed and leaving a plural walled hollowmetal body, said plnralit I of metal bodies being rela,- tively'connec ed to one another. 1

8. `A process for making hollow metal bodies comprised of a. plurality of 'metal bodies one inside the other and tour consisting of molding into shape Va core form comprised of terial of low melting point, and

the desired fusible macovering the' body of metal formed thereby the same with a coating electro-deposited metal and again coatin the said enter metal bodTWith-nothercoating of fusible material,\another coatof metal being electro-deposited thereon and the metal bodies mined points and fusing out the forms thereby leaving a plurality of hollow contour one inside the EDWARDv G., soon.

o' the ends of said metal of like con-` electrode! positing thereon a coating of metal and then tabel,

of 'A 

